notice of decision: approval - effective immediatelypermits.air.idem.in.gov/26448f.pdfpursuant to...

INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENTWe Protect Hoosiers and Our Environment.

Mitchell E. Daniels Jr. 100 North Senate Avenue Governor Indianapolis, Indiana 46204 (317) 232-8603 Thomas W. Easterly Toll Free (800) 451-6027 Commissioner www.idem.IN.gov

Recycled Paper An Equal Opportunity Employer Please Recycle

TO: Interested Parties / Applicant DATE: June 26, 2008 RE: New Horizons Baking Company / 151-26448-00060 FROM: Matthew Stuckey, Branch Chief Permits Branch

Office of Air Quality

Notice of Decision: Approval - Effective Immediately

Please be advised that on behalf of the Commissioner of the Department of Environmental Management, I have issued a decision regarding the enclosed matter. Pursuant to IC 13-17-3-4 and 326 IAC 2, this approval is effective immediately, unless a petition for stay of effectiveness is filed and granted, and may be revoked or modified in accordance with the provisions of IC 13-15-7-1. If you wish to challenge this decision, IC 4-21.5-3-7 and IC 13-15-7-3 require that you file a petition for administrative review. This petition may include a request for stay of effectiveness and must be submitted to the Office Environmental Adjudication, 100 North Senate Avenue, Government Center North, Suite N 501E, Indianapolis, IN 46204, within eighteen (18) calendar days of the mailing of this notice. The filing of a petition for administrative review is complete on the earliest of the following dates that apply to the filing: (1) the date the document is delivered to the Office of Environmental Adjudication (OEA); (2) the date of the postmark on the envelope containing the document, if the document is mailed to

OEA by U.S. mail; or (3) The date on which the document is deposited with a private carrier, as shown by receipt issued

by the carrier, if the document is sent to the OEA by private carrier. The petition must include facts demonstrating that you are either the applicant, a person aggrieved or adversely affected by the decision or otherwise entitled to review by law. Please identify the permit, decision, or other order for which you seek review by permit number, name of the applicant, location, date of this notice and all of the following: (1) the name and address of the person making the request; (2) the interest of the person making the request; (3) identification of any persons represented by the person making the request; (4) the reasons, with particularity, for the request; (5) the issues, with particularity, proposed for considerations at any hearing; and (6) identification of the terms and conditions which, in the judgment of the person making the

request, would be appropriate in the case in question to satisfy the requirements of the law governing documents of the type issued by the Commissioner.

If you have technical questions regarding the enclosed documents, please contact the Office of Air Quality, Permits Branch at (317) 233-0178. Callers from within Indiana may call toll-free at 1-800-451-6027, ext. 3-0178.

Enclosures FNPER-MOD.dot 12/3/07

INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENTWe Protect Hoosiers and Our Environment.



Mark Duke New Horizons Baking Company 700 W. Water Street Fremont, Indiana 46737

Re: 151-26448-00060 First Minor Revision to M 151-17821-00060

Dear Mr. Duke:

New Horizons Baking Company was issued a Minor Source Operating Permit (MSOP) No. M 151-17821-00060 on October 16, 2003 for a stationary bread baking plant located at 700 W. Water Street, Fremont, IN, 46737. On April 17, 2008, the Office of Air Quality (OAQ) received an application from the source requesting the heat input to the muffin griddle, identified as Unit B, be increased to 5.96 MMBtu/hour and the maximum muffin production rate be increased to 2.10 tons/hour. Based on the revised production rate, the potential VOC emissions of the muffin griddle are greater than 25 tons/year. However, the source has agreed to limit the VOC emissions from the muffin griddle to less than 25 tons/year rendering the requirements of 326 IAC 8-1-6 not applicable. Pursuant to the provisions of 326 IAC 2-6.1-6, these changes to the permit are required to be reviewed in accordance with the Minor Permit Revision (MPR) procedures of 326 IAC 2-6.1-6(h). The table below summarizes the revised potential to emit of the entire source, with updated emissions shown as bold values and previous emissions shown as strikethrough values.

Potential To Emit After Issuance (tons/year)

Process/emission unit PM PM-10 SO2 NOx VOC CO HAPs

Space Heaters 0.02 0.02 0.002 0.26 0.01 0.22 NegligibleBoilers 0.15 0.15 0.01 1.93 0.11 1.62 Negligible

Bun and Muffin Ovens (Combustion)

0.22 0.10

0.22 0.40

0.02 0.03

2.91 4.60

0.16 0.30

2.44 3.90

Negligible

Bun Making Ovens (Fermentation)

- - - - 62.2 - -

Muffin Griddle (Fermentation)

- - - - 28.9 24.9

- -

Emergency Generator 3.4E-05 3.4E-05 2.0E-06 2.9E-03 4.0E-04 1.9E-03 - Silos 0.96 0.96 - - - - -

Total Emissions (After Modification)

1.35 1.23

1.35 1.53

0.03 0.04

5.10 6.79

91.3 87.5

4.29 5.74

Negligible

Proposed Changes

New Horizons Baking Company Page 2 of 8 Fremont, Indiana MSOP MPR No. 151-26448-00060 Permit Reviewer: Timothy R. Pettifor The following changes listed below are due to the proposed revision. Deleted language appears as strikethrough text and new language appears as bold text:

(1) The description of the muffin griddle (Unit B) in Condition A.2 and Section D.1 has been updated to reflect the increase in heat input and bread production.

(2) Potential VOC emissions from the muffin griddle have been calculated using an emission

factor based on the following equation from the American Institute of Bakers: Ei = 0.40425 + 0.444585 [(Yi x ti) + (S x ts)] where: Ei = The VOC emission factor for type i bread (lb of VOC/ton of baked bread); Yi = The baker’s percent of yeast in sponge; ti = The total time of fermentation in hours; S = The baker's percent yeast added to dough; and ts = The proof time plus the floor time in hours.

The source states this equation most accurately represents the operating parameters of the muffin griddle. IDEM has agreed to allow the source to use this equation. Using information provided by the source, the emission factor was calculated to be 3.11 lb of VOC/ton of baked bread. Therefore, the potential VOC emissions from the muffin griddle are 28.6 tons/year (3.11 lb VOC/ton of baked bread x 2.10 tons of bread/hour x 8760 hours/year x 1 ton/ 2000 lbs = 28.6 tons/year). The source has agreed to limit the VOC emissions from the muffin griddle to less than 25 tons/year, in order to render the requirements of 326 IAC 8-1-6 (New facilities; general reduction requirements) not applicable. This VOC limit has been added as Condition D.1.2.

(3) Compliance determination, recordkeeping, and reporting requirements have been added

to Section D.1. These requirements are necessary to determine the source's compliance with the VOC limit in Condition D.1.2. A reporting form has also been added to the end of the permit.

Pursuant to the provisions of 326 IAC 2-6.1-6, the permit is hereby revised as follows with the deleted language as strikeouts and new language bolded.

A.2 Emissions Units and Pollution Control Equipment Summary This stationary source is approved to operate the following emissions units and pollution control devices:

...

(b) One (1) natural gas fired muffin griddle (identified as Unit B), with a maximum heat input capacity of 2.04 5.96 MMBtu per hour and a maximum baking rate of 3,300 pounds 2.10 tons of bread per hour, and exhausting at Stack B. This unit was constructed in 1983.

...

New Horizons Baking Company Page 3 of 8 Fremont, Indiana MSOP MPR No. 151-26448-00060 Permit Reviewer: Timothy R. Pettifor SECTION D.1 EMISSIONS UNIT OPERATION CONDITIONS

Facility Description [326 IAC 2-6.1]: ... (b) One (1) natural gas fired muffin griddle (identified as Unit B), with a maximum heat input

capacity of 2.04 5.96 MMBtu per hour and a maximum baking rate of 3,300 pounds 2.10 tons of bread per hour, and exhausting at Stack B. This unit was constructed in 1983.

(The information describing the process contained in this facility description box is descriptive information and does not constitute enforceable conditions.)

... D.1.2 Volatile Organic Compound (VOC) Limitations [326 IAC 8-1-6]

The potential to emit VOC from the muffin griddle (identified as Unit B) shall be less than 25.0 tons per twelve (12) consecutive month period with compliance determined at the end of each month.

Compliance with this limit renders the requirements of 326 IAC 8-1-6 (New facilities; General reduction requirements) not applicable.

D.1.32 Particulate [326 IAC 6-3-2]

Pursuant to 326 IAC 6-3-2 (Particulate Emission Limitations for Manufacturing Processes), the particulate emissions from the bun making oven and muffin griddle shall not exceed 10.1 pounds per hour and 5.73 pounds per hour when operating at a process weight rate of 3.85 tons per hour and 1.65 tons per hour, respectively.

The pounds per hour limitation was calculated using the following equation:

Interpolation of the data for the process weight rate up to sixty thousand (60,000) pounds per hour shall be accomplished by use of the equation:

E = 4.10 P0.67 where E = rate of emission in pounds per hour and

P = process weight rate in tons per hour D.1.43 Preventive Maintenance Plan [326 IAC 1-6-3]

A Preventive Maintenance Plan, in accordance with Section C - Preventive Maintenance Plan, of this permit, is required for the bun oven facility.

Compliance Monitoring Requirements [326 IAC 2-5.1-3(e)(2)] [326 IAC 2-6.1-5(a)(2)] D.1.5 VOC Emissions

Compliance with Condition D.1.2 shall be determined within 30 days of the end of each month. For a particular month, this shall be based on the total volatile organic compound emitted for that month added to the previous eleven (11)-month total VOC emitted so as to arrive at VOC emissions for the most recent twelve (12) consecutive month period. The VOC emissions for a month shall be determined using the following equation:

∑=

=n

1i

iii ton/lbs2000

BEVOC

New Horizons Baking Company Page 4 of 8 Fremont, Indiana MSOP MPR No. 151-26448-00060 Permit Reviewer: Timothy R. Pettifor

where:

VOCi = The total VOC emissions per month from the muffin griddle for all bread types; Bi = The amount of bread of type i produced during a given month (tons/month); Ei = The VOC emission factor for type i bread (lb of VOC/ton of baked bread); and n = The total number of bread types produced during a given month.

The VOC emission factor for each type of bread made in the muffin griddle shall be calculated using the following equation:

Ei = 0.40425 + 0.444585 [(Yi x ti) + (S x ts)] where: Ei = The VOC emission factor for type i bread (lb of VOC/ton of baked bread); Yi = The baker’s percent of yeast in sponge; ti = The total time of fermentation in hours; S = The baker's percent yeast added to dough; and ts = The proof time plus the floor time in hours.

D.1.64 Visible Emissions Notations

(a) Visible emission notations of the bun oven stack exhaust shall be performed once per shift during normal daylight operations when exhausting to the atmosphere. A trained employee shall record whether emissions are normal or abnormal.

(b) For processes operated continuously, "normal" means those conditions prevailing, or

expected to prevail, eighty percent (80%) of the time the process is in operation, not counting startup or shut down time.

(c) In the case of batch or discontinuous operations, readings shall be taken during that part

of the operation that would normally be expected to cause the greatest emissions.

(d) A trained employee is an employee who has worked at the plant at least one (1) month and has been trained in the appearance and characteristics of normal visible emissions for that specific process.

(e) The Compliance Response Plan for this unit shall contain troubleshooting contingency

and response steps for when an abnormal emission is observed. Failure to take response steps in accordance with Section C - Compliance Response Plan - Preparation and Implementation shall be considered a violation of this permit.

Record Keeping and Reporting Requirement D.1.75 Record Keeping Requirements

(a) To document compliance with Condition D.1.4, the Permittee shall maintain records of visible emission notations of the bun oven stack exhaust once per shift.

(b) To document compliance with Condition D.1.3, the Permittee shall maintain records of

any additional inspections prescribed by the Preventive Maintenance Plan.

(c) To document compliance with Condition D.1.1, the Permittee shall maintain records of the emission factor (in pounds of VOC per ton of baked bread) calculated using the equation in AP-42, Chapter 9.9.6 -Bread Baking (February 1997).

(c) To document compliance with Condition D.1.2, the Permittee shall maintain records


in accordance with (1) through (4) below. Records maintained for (1) through (4) shall be taken as stated below and shall be complete and sufficient to establish compliance with the VOC emissions limit established in Condition D.1.2.

(1) The dates of the compliance period:

(2) The amount and type of each bread produced during each month; (3) The VOC emission factor for each type of bread made during each month

and information necessary to calculate the VOC emission factor for each type of bread, including:

(A) The baker’s percent of yeast in sponge;

(B) The total time of fermentation in hours;

(C) The baker's percent yeast added to dough; and

(D) The proof time plus the floor time in hours.

(4) The total weight of VOCs emitted for each month.

(d) All records shall be maintained in accordance with Section C - General Record Keeping

Requirements, of this permit. D.1.8 Reporting Requirements

A quarterly summary of the information to document compliance with Condition D.1.2 shall be submitted to the addresses listed in Section C - General Reporting Requirements, of this permit, using the reporting forms located at the end of this permit, or their equivalent, within thirty (30) days after the end of the quarter being reported.


INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT OFFICE OF AIR QUALITY COMPLIANCE DATA SECTION

MSOP Quarterly Report

Source Name: New Horizons Baking Company Source Address: 700 W. Water Street, Fremont, Indiana 46737 Mailing Address: 700 W. Water Street, Fremont, Indiana 46737 MSOP No.: 151-17821-00060 Facility: The muffin griddle (identified as Unit B) Parameter: Volatile Organic Compound (VOC) Emissions Limit: Less than 25.0 tons per twelve (12) consecutive month period, with compliance

determined at the end of each month. The VOC emissions for a month shall be determined using the equations contained in Condition D.1.5

YEAR:_____________________

VOC Emissions (tons) VOC Emissions (tons) VOC Emissions (tons) Month

This Month Previous 11 Months 12 Month Total

No deviation occurred in this quarter. Deviation/s occurred in this quarter.

Deviation has been reported on: _________________

Submitted by: ____________________________________________________

Title / Position: ___________________________________________________

Signature: _______________________________________________________

Date: ____________________________________________________________

Phone: __________________________________________________________

IDEM, OAQ has decided to make additional revisions to the permit as described below. The

New Horizons Baking Company Page 7 of 8 Fremont, Indiana MSOP MPR No. 151-26448-00060 Permit Reviewer: Timothy R. Pettifor permit is revised as follows with deleted language as strikeouts and new language bolded: (a) All occurrences of IDEM's mailing addresses have been updated in the permit. Any occurrences

of P.O. Box 6015 in the permit have been removed, any occurrences of the zip code 46206-6015 or 46204 have been revised to 46204-2251, and all addresses have been revised to include a mail code (MC) as follows:

Asbestos Section: MC 61-52 IGCN 1003 Compliance Branch: MC 61-53 IGCN 1003 Permits Branch: MC 61-53 IGCN 1003 Technical Support and Modeling Section: MC 61-50 IGCN 1003

(b) IDEM has begun implementing a new procedure and will no longer list the name or title of the

Authorized Individual (A.I.) in the permit document. Section A.1 is updated as follows: Authorized Individual: Vice President

(c) A typographical error in Condition C.13 has been corrected as follows. C.13 General Reporting Requirements [326 IAC 2-1.1-11] [326 IAC 2-6.1-2] [IC 13-14-1-13] ...

(c) Unless otherwise specified in this permit, any reports required in Section D of this permit shall be submitted within thirty (30) days of the end of the reporting period. The reports do not require the certification by an “authorized individual” as defined by 326 IAC 2-1.1-1(1).

(d) The source address has been updated in the permit and reporting forms as follows: 5700 North West Street 700 W. Water Street Fremont, Indiana 46737

Pursuant to 326 IAC 2-6.1-6, this permit shall be revised by incorporating the minor permit revision into the permit. All other conditions of the permit shall remain unchanged and in effect. Attached please find the entire revised permit.

This decision is subject to the Indiana Administrative Orders and Procedures Act - IC 4-21.5-3-5. If you have any questions on this matter, please contact Timothy R. Pettifor, of my staff, at 317-234-5300 or 1-800-451-6027, and ask for extension 4-5300.

Sincerely,

Alfred C. Dumaual, Ph. D., Section Chief Permits Branch Office of Air Quality

Attachments: calculations and revised permit ACD/TP cc: File - Steuben County

Steuben County Health Department


U.S. EPA, Region V Air Compliance Section Northern Regional Office Compliance Data Section Technical Support and Modeling Permits Administrative and Development Billing, Licensing and Training Section

INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT We Protect Hoosiers and Our Environment.



MINOR SOURCE OPERATING PERMIT OFFICE OF AIR QUALITY

New Horizons Baking Company 700 W. Water Street

Fremont, Indiana 46737

(herein known as the Permittee) is hereby authorized to operate subject to the conditions contained herein, the emission units described in Section A (Source Summary) of this permit.

This permit is issued to the above mentioned company under the provisions of 326 IAC 2-1.1, 326 IAC 2-6.1 and 40 CFR 52.780, with conditions listed on the attached pages.

Operation Permit No.: MSOP 151-17821-00060

Original Signed by: Paul Dubenetzky, Branch Chief Permits Branch Office of Air Quality

Issuance Date: October 16, 2003 Expiration Date: October 16, 2008

1st Minor Permit Revision No.: MSOP 151-26448-00060

Issued by: Original Signed By: Alfred C. Dumaual, Ph.D., Section Chief Permits Branch Office of Air Quality

Issuance Date: June 26, 2008 Expiration Date: October 16, 2008

New Horizons Baking Company Page 2 of 25 Fremont, Indiana Changed by: Timothy R. Pettifor MSOP 151-17821-00060 Permit Reviewer: ERG/SD

1st Minor Permit Revision No. 151-26448-00060

TABLE OF CONTENTS

SECTION A SOURCE SUMMARY ......................................................................................................... 4 A.1 General Information [326 IAC 2-5.1-3(c)] [326 IAC 2-6.1-4(a)] A.2 Emission Units and Pollution Control Equipment Summary

SECTION B GENERAL CONDITIONS ................................................................................................... 5

B.1 Permit No Defense [IC 13] B.2 Definitions B.3 Effective Date of the Permit [IC 13-15-5-3] B.4 Permit Term and Renewal [326 IAC 2-6.1-7(a)][326 IAC 2-1.1-9.5] B.5 Modification to Permit [326 IAC 2] B.6 Annual Notification [326 IAC 2-6.1-5(a)(5)] B.7 Preventive Maintenance Plan [326 IAC 1-6-3] B.8 Permit Revision [326 IAC 2-5.1-3(e)(3)] [326 IAC 2-6.1-6] B.9 Inspection and Entry [326 IAC 2-5.1-3(e)(4)(B)] [326 IAC 2-6.1-5(a)(4)] [IC 13-14-2-2]

[IC 13-20-3-1] B.10 Transfer of Ownership or Operation [326 IAC 2-6.1-6(d)(3)] B.11 Annual Fee Payment [326 IAC 2-1.1-7]

SECTION C SOURCE OPERATION CONDITIONS............................................................................... 9

C.1 Particulate Emission Limitations For Processes with Process Weight Rates Less Than One Hundred (100) pounds per hour [326 IAC 6-3-2]

C.2 Permit Revocation [326 IAC 2-1.1-9] C.3 Opacity [326 IAC 5-1] C.4 Fugitive Dust Emissions [326 IAC 6-4] C.5 Asbestos Abatement Projects [326 IAC 14-10][326 IAC 18][40 CFR 61, Subpart M]

Testing Requirements C.6 Performance Testing [326 IAC 3-6]

Compliance Requirements [326 IAC 2-1.1-11] C.7 Compliance Requirements [326 IAC 2-1.1-11]

Compliance Monitoring Requirements C.8 Compliance Monitoring [326 IAC 2-1.1-11] C.9 Monitoring Methods [326 IAC 3] [40 CFR 60][40 CFR 63] C.10 Compliance Response Plan - Preparation and Implementation

Record Keeping and Reporting Requirements C.11 Malfunctions Report [326 IAC 1-6-2] C.12 General Record Keeping Requirements [326 IAC 2-6.1-5] C.13 General Reporting Requirements [326 IAC 2-1.1-11] [326 IAC 2-6.1-2] [IC 13-14-1-13]

SECTION D.1 FACILITY OPERATION CONDITIONS ........................................................................... 15

Emission Limitations and Standards [326 IAC 2-6.1-5 (a)(1)] D.1.1 Volatile Organic Compounds (VOCs) [326 IAC 2-7] D.1.2 Volatile Organic Compounds (VOCs) [326 IAC 8-1-6] D.1.3 Particulate [326 IAC 6-3-2] D.1.4 Preventive Maintenance Plan [326 IAC 1-6-3]

Compliance Monitoring Requirements [326 IAC 2-5.1-3(e)(2)][326 IAC 2-6.1-5(1)(2)] D.1.5 VOC Emissions



D.1.6 Visible Emission Notations Record Keeping and Reporting Requirement D.1.7 Record Keeping Requirements D.1.8 Reporting Requirements

SECTION D.2 FACILITY OPERATION CONDITIONS .......................................................................... 18

Emission Limitations and Standards D.2.1 Particulate [326 IAC 6-3-2]

Compliance Determination Requirements D.2.2 Particulate Control


Emission Limitations and Standards D.3.1 Particulate [326 IAC 6-2-3] D.3.2 Particulate [326 IAC 6-2-4]


Emission Limitations and Standards D.4.1 Limitation on Operating Hours Record Keeping and Reporting Requirements [326 IAC 2-5.1-3(e)(2)][326 IAC 2-6.1-5(a)(2)] D.4.2 Record Keeping Requirements


Emission Limitations and Standards Annual Notification ...................................................................................................................................... 22 Malfunction Report ...................................................................................................................................... 23 MSOP Quaterly Report ............................................................................................................................... 25



SECTION A SOURCE SUMMARY This permit is based on information requested by the Indiana Department of Environmental Management (IDEM), Office of Air Quality (OAQ). The information describing the source contained in conditions A.1 and A.2 is descriptive information and does not constitute enforceable conditions. However, the Permittee should be aware that a physical change or a change in the method of operation that may render this descriptive information obsolete or inaccurate may trigger requirements for the Permittee to obtain additional permits or seek modification of this permit pursuant to 326 IAC 2, or change other applicable requirements presented in the permit application. A.1 General Information [326 IAC 2-5.1-3(c)] [326 IAC 2-6.1-4(a)]

The Permittee owns and operates a stationary bread baking plant. Source Address: 700 W. Water Street, Fremont, Indiana 46737 Mailing Address: 700 W. Water Street, Fremont, Indiana 46737 General Source Phone: (260) 495-7055 SIC Code: 2051 County Location: Steuben Source Location Status: Attainment for all criteria pollutants Source Status: Minor Source, under PSD Rules;

Minor Source, Section 112 of the Clean Air Act Not 1 of 28 Source Categories

A.2 Emissions Units and Pollution Control Equipment Summary

This stationary source is approved to operate the following emissions units and pollution control devices:

(a) One (1) natural gas fired bun oven (identified as Unit A), with a maximum heat input

capacity of 4.60 MMBtu per hour and a maximum baking rate of 7,700 pounds of bread per hour, and exhausting at Stack A. This unit was constructed in 1979.

(b) One (1) natural gas fired muffin griddle (identified as Unit B), with a maximum heat input

capacity of 5.96 MMBtu per hour and a maximum baking rate of 2.10 tons of bread per hour, and exhausting at Stack B. This unit was constructed in 1983.

(c) Two (2) flour storage silos (identified as Unit C1 and C2), each with a maximum capacity

of 60 tons and a maximum throughput rate of 6.25 tons of flour per hour, equipped with a pneumatic conveyance system, using fabric filters as control. These units were constructed in 1979.

(d) One (1) natural gas fired Hurst boiler (identified as Unit D), with a maximum heat input

capacity of 2.60 MMBtu per hour and exhausting at Stack D. This unit was constructed in 1979.

(e) One (1) natural gas fired Kewanee boiler (identified as Unit E), with a maximum heat input

capacity of 1.80 MMBtu per hour and exhausting at Stack E. This unit was constructed in 1996.

(f) One (1) 5 KVA emergency generator (identified as Unit G), burning natural gas and

exhausting at Stack G. This unit was constructed in 1983.

(g) Six (6) natural gas fired space heaters (identified as F1 through F6), each with a maximum heat input capacity of 0.10 MMBtu per hour. These units were installed in 1979.



SECTION B GENERAL CONDITIONS THIS SECTION OF THE PERMIT IS BEING ISSUED UNDER THE PROVISIONS OF 326 IAC 2-1.1 AND 40 CFR 52.780, WITH CONDITIONS LISTED BELOW. B.1 Permit No Defense [IC 13]

This permit to operate does not relieve the Permittee of the responsibility to comply with the provisions of the Indiana Environmental Management Law (IC 13-11 through 13-20; 13-22 through 13-25; and 13-30), the Air Pollution Control Law (IC 13-17) and the rules promulgated thereunder, as well as other applicable local, state, and federal requirements.

B.2 Definitions

Terms in this permit shall have the definition assigned to such terms in the referenced regulation. In the absence of definitions in the referenced regulation, the applicable definitions found in the statutes or regulations IC 13-11, 326 IAC 1-2, and 326 IAC 2-1.1-1 shall prevail.

B.3 Effective Date of the Permit [IC13-15-5-3]

Pursuant to IC 13-15-5-3, this permit becomes effective upon its issuance. B.4 Permit Term and Renewal [326 IAC 2-6.1-7(a)][326 IAC 2-1.1-9.5]

This permit is issued for a fixed term of five (5) years from the issuance date of this permit, as determined in accordance with IC 4-21.5-3-5(f) and IC 13-15-5-3. Subsequent revisions of this permit do not affect the expiration date.

The Permittee shall apply for an operation permit renewal at least ninety (90) days prior to the expiration date. If a timely and sufficient permit application for a renewal has been made, this permit shall not expire and all terms and conditions shall continue in effect until the renewal permit has been issued or denied.

B.5 Modification to Permit [326 IAC 2]

All requirements and conditions of this operating permit shall remain in effect unless modified in a manner consistent with procedures established for modifications of construction permits pursuant to 326 IAC 2 (Permit Review Rules).

B.6 Annual Notification [326 IAC 2-6.1-5(a)(5)]

(a) Annual notification shall be submitted to the Office of Air Quality stating whether or not the source is in operation and in compliance with the terms and conditions contained in this permit.

(b) Noncompliance with any condition must be specifically identified. If there are any permit

conditions or requirements for which the source is not in compliance at any time during the year, the Permittee must provide a narrative description of how the source did or will achieve compliance and the date compliance was, or will be, achieved. The notification must be signed by an authorized individual.

(c) The annual notice shall cover the time period from January 1 to December 31 of the

previous year, and shall be submitted in the format attached no later than March 1 of each year to:

Compliance Branch, Office of Air Quality Indiana Department of Environmental Management 100 North Senate Avenue MC 61-53 IGCN 1003 Indianapolis, IN 46204-2251



(d) The notification shall be considered timely if the date postmarked on the envelope or certified mail receipt, or affixed by the shipper on the private shipping receipt, is on or before the date it is due. If the document is submitted by any other means, it shall be considered timely if received by IDEM, OAQ, on or before the date it is due.

B.7 Preventive Maintenance Plan [326 IAC 1-6-3]

(a) If required by specific condition(s) in Section D of this permit, the Permittee shall maintain and implement Preventive Maintenance Plans (PMPs) within 90 days after issuance of this permit, including the following information on each emissions unit:

(1) Identification of the individual(s) responsible for inspecting, maintaining, and

repairing emission control devices;

(2) A description of the items or conditions that will be inspected and the inspection schedule for said items or conditions; and

(3) Identification and quantification of the replacement parts that will be maintained in

inventory for quick replacement.

If, due to circumstances beyond the Permittee’s control, the PMPs cannot be prepared and maintained within the above time frame, the Permittee may extend the date an additional ninety (90) days provided the Permittee notifies:

Indiana Department of Environmental Management Compliance Branch, Office of Air Quality 100 North Senate Avenue MC 61-53 IGCN 1003 Indianapolis, Indiana 46204-2251 The PMP extension notification does not require the certification by an “authorized individual” as defined by 326 IAC 2-1.1-1(1).

(b) The Permittee shall implement the PMPs, including any required record keeping, as

necessary to ensure that failure to implement a PMP does not cause or contribute to an exceedance of any limitation on emissions or potential to emit.

(c) A copy of the PMPs shall be submitted to IDEM, OAQ, upon request and within a

reasonable time, and shall be subject to review and approval by IDEM, OAQ. IDEM, OAQ, may require the Permittee to revise its PMPs whenever lack of proper maintenance causes or is the primary contributor to an exceedance of any limitation on emissions or potential to emit. The PMP does not require the certification by the “authorized individual” as defined by 326 IAC 2-1.1-1(1).

(d) To the extent the Permittee is required by 40 CFR Part 60/63 to have an Operation,

Maintenance, and Monitoring (OMM) Plan for a unit, such Plan is deemed to satisfy the PMP requirements of 326 IAC 1-6-3 for that unit.

B.8 Permit Revision [326 IAC 2-5.1-3(e)(3)] [326 IAC 2-6.1-6]

(a) Permit revisions are governed by the requirements of 326 IAC 2-6.1-6.

(b) Any application requesting an amendment or modification of this permit shall be submitted to:

Indiana Department of Environmental Management Permits Branch, Office of Air Quality



100 North Senate Avenue MC 61-53 IGCN 1003 Indianapolis, Indiana 46204-2251

Any such application shall be certified by an “authorized individual” as defined by 326 IAC 2-1.1-1.

(c) The Permittee shall notify the OAQ within thirty (30) calendar days of implementing a

notice-only change. [326 IAC 2-6.1-6(d)]

(d) No permit amendment or modification is required for the addition, operation or removal of a nonroad engine, as defined in 40 CFR 89.2.

B.9 Inspection and Entry [326 IAC 2-5.1-3(e)(4)(B)] [326 IAC 2-6.1-5(a)(4)][IC 13-14-2-2] [IC13-30-3-1]

Upon presentation of proper identification cards, credentials, and other documents as may be required by law, and subject to the Permittee’s right under all applicable laws and regulations to assert that the information collected by the agency is confidential and entitled to be treated as such, the Permittee shall allow IDEM, OAQ, U.S. EPA, or an authorized representative to perform the following:

(a) Enter upon the Permittee's premises where a permitted source is located, or emissions

related activity is conducted, or where records must be kept under the conditions of this permit;

(b) As authorized by the Clean Air Act, IC 13-14-2-2, IC 13-17-3-2, and IC 13-30-3-1, have

access to and copy, at reasonable times, any records that must be kept under this title or the conditions of this permit or any operating permit revisions;

(c) As authorized by the Clean Air Act, IC 13-14-2-2, IC 13-17-3-2, and IC 13-30-3-1, inspect,

at reasonable times, any processes, emissions units (including monitoring and air pollution control equipment), practices, or operations regulated or required under this permit or any operating permit revisions;

(d) As authorized by the Clean Air Act, IC 13-14-2-2, IC 13-17-3-2, and IC 13-30-3-1, sample

or monitor, at reasonable times, substances or parameters for the purpose of assuring compliance with this permit or applicable requirements; and

(e) As authorized by the Clean Air Act, IC 13-14-2-2, IC 13-17-3-2, and IC 13-30-3-1, utilize

any photographic, recording, testing, monitoring, or other equipment for the purpose of assuring compliance with this permit or applicable requirements.

B.10 Transfer of Ownership or Operation [326 IAC 2-6.1-6(d)(3)]

Pursuant to [326 IAC 2-6.1-6(d)(3)] :

(a) In the event that ownership of this source is changed, the Permittee shall notify IDEM, OAQ, Permits Branch, within thirty (30) days of the change.

(b) The written notification shall be sufficient to transfer the permit to the new owner by an

notice-only change pursuant to 326 IAC 2-6.1-6(d)(3).

(c) IDEM, OAQ, shall issue a revised permit.

The notification which shall be submitted by the Permittee does require the certification by the “authorized individual” as defined by 326 IAC 2-1.1-1.

New Horizons Baking Company Page 8 of 25 Fremont, Indiana MSOP 151-17821-00060 Permit Reviewer: ERG/SD

1st Minor Permit Revision No. 151-26448-00060 Changed by: Timothy R. Pettifor

B.11 Annual Fee Payment [326 IAC 2-1.1-7] (a) The Permittee shall pay annual fees to IDEM, OAQ within thirty (30) calendar days of

receipt of a billing.

(b) The Permittee may call the following telephone numbers: 1-800-451-6027 or 317-233-4230 (ask for OAQ, I/M & Billing Section), to determine the appropriate permit fee.



SECTION C SOURCE OPERATION CONDITIONS

Entire Source

C.1 Particulate Emission Limitations For Processes with Process Weight Rates Less Than One

Hundred (100) pounds per hour [326 IAC 6-3-2] Pursuant to 326 IAC 6-3-2(e)(2), particulate emissions from any process not exempt under 326 IAC 6-3-1(b) or (c) which has a maximum process weight rate less than 100 pounds per hour and the methods in 326 IAC 6-3-2(b) through (d) do not apply shall not exceed 0.551 pounds per hour.

C.2 Permit Revocation [326 IAC 2-1.1-9]

Pursuant to 326 IAC 2-1.1-9 (Revocation of Permits), this permit operate may be revoked for any of the following causes:

(a) Violation of any conditions of this permit.

(b) Failure to disclose all the relevant facts, or misrepresentation in obtaining this permit.

(c) Changes in regulatory requirements that mandate either a temporary or permanent

reduction of discharge of contaminants. However, the amendment of appropriate sections of this permit shall not require revocation of this permit.

(d) Noncompliance with orders issued pursuant to 326 IAC 1-5 (Episode Alert Levels) to

reduce emissions during an air pollution episode.

(e) For any cause which establishes in the judgment of IDEM, the fact that continuance of this permit is not consistent with purposes of this article.

C.3 Opacity [326 IAC 5-1]

Pursuant to 326 IAC 5-1-2 (Opacity Limitations), except as provided in 326 IAC 5-1-3 (Temporary Alternative Opacity Limitations), opacity shall meet the following, unless otherwise stated in this permit:

(a) Opacity shall not exceed an average of forty percent (40%) in any one (1) six (6) minute

averaging period as determined in 326 IAC 5-1-4.

(b) Opacity shall not exceed sixty percent (60%) for more than a cumulative total of fifteen (15) minutes (sixty (60) readings as measured according to 40 CFR 60, Appendix A, Method 9 or fifteen (15) one (1) minute nonoverlapping integrated averages for a continuous opacity monitor) in a six (6) hour period.

C.4 Fugitive Dust Emissions [326 IAC 6-4]

The Permittee shall not allow fugitive dust to escape beyond the property line or boundaries of the property, right-of-way, or easement on which the source is located, in a manner that would violate 326 IAC 6-4 (Fugitive Dust Emissions).

C.5 Asbestos Abatement Projects [326 IAC 14-10] [326 IAC 18] [40 CFR 61, Subpart M]

(a) Notification requirements apply to each owner or operator. If the combined amount of regulated asbestos containing material (RACM) to be stripped, removed or disturbed is at least 260 linear feet on pipes or 160 square feet on other facility components, or at least thirty-five (35) cubic feet on all facility components, then the notification requirements of 326 IAC 14-10-3 are mandatory. All demolition projects require notification whether or not asbestos is present.



(b) The Permittee shall ensure that a written notification is sent on a form provided by the Commissioner at least ten (10) working days before asbestos stripping or removal work or before demolition begins, per 326 IAC 14-10-3, and shall update such notice as necessary, including, but not limited to the following:

(1) When the amount of affected asbestos containing material increases or

decreases by at least twenty percent (20%); or

(2) If there is a change in the following:

(A) Asbestos removal or demolition start date;

(B) Removal or demolition contractor; or

(C) Waste disposal site.

(c) The Permittee shall ensure that the notice is postmarked or delivered according to the guidelines set forth in 326 IAC 14-10-3(2).

(d) The notice to be submitted shall include the information enumerated in

326 IAC 14-10-3(3).

All required notifications shall be submitted to:

Indiana Department of Environmental Management Asbestos Section, Office of Air Quality 100 North Senate Avenue MC 61-52 IGCN 1003 Indianapolis, Indiana 46204-2251

The notice shall include a signed certification from the owner or operator that the information provided in this notification is correct and that only Indiana licensed workers and project supervisors will be used to implement the asbestos removal project. The notifications do not require a certification by an “authorized individual” as defined by 326 IAC 2-7-1(34).

(e) Procedures for Asbestos Emission Control

The Permittee shall comply with the applicable emission control procedures in 326 IAC 14-10-4 and 40 CFR 61.145(c). Per 326 IAC 14-10-1, emission control requirements are applicable for any removal or disturbance of RACM greater than three (3) linear feet on pipes or three (3) square feet on any other facility components or a total of at least 0.75 cubic feet on all facility components.

(f) Demolition and Renovation

The Permittee shall thoroughly inspect the affected facility or part of the facility where the demolition or renovation will occur for the presence of asbestos pursuant to 40 CFR 61.145(a).

(g) Indiana Accredited Asbestos Inspector

The Permittee shall comply with 326 IAC 14-10-1(a) that requires the owner or operator, prior to a renovation/demolition, to use an Indiana Accredited Asbestos Inspector to thoroughly inspect the affected portion of the facility for the presence of asbestos. The requirement to use an Indiana Accredited Asbestos inspector is not federally enforceable.



Testing Requirements C.6 Performance Testing [326 IAC 3-6]

(a) Compliance testing on new emissions units shall be conducted within 60 days after achieving maximum production rate, but no later than180 days after initial start-up, if specified in Section D of this approval. All testing shall be performed according to the provisions of 326 IAC 3-6 (Source Sampling Procedures), except as provided elsewhere in this permit, utilizing any applicable procedures and analysis methods specified in 40 CFR 51, 40 CFR 60, 40 CFR 61, 40 CFR 63, 40 CFR 75, or other procedures approved by IDEM, OAQ.

A test protocol, except as provided elsewhere in this permit, shall be submitted to:

Indiana Department of Environmental Management Compliance Data Section, Office of Air Quality 100 North Senate Avenue MC 61-53 IGCN 1003 Indianapolis, Indiana 46204-2251

no later than thirty-five (35) days prior to the intended test date.

(b) The Permittee shall notify IDEM, OAQ of the actual test date at least fourteen (14 days)

prior to the actual date.

(c) Pursuant to 326 IAC 3-6-4(b), all test reports must be received by IDEM, OAQ not later than forty-five (45) days after the completion of the testing. An extension may be granted by the IDEM, OAQ, if the source submits to IDEM, OAQ, a reasonable written explanation not later than five (5) days prior to the end of the initial forty-five (45) day period.

Compliance Requirements [326 IAC 2-1.1-11] C.7 Compliance Requirements [326 IAC 2-1.1-11]

The commissioner may require stack testing, monitoring, or reporting at any time to assure compliance with all applicable requirements by issuing an order under 326 IAC 2-1.1-11. Any monitoring or testing shall be performed in accordance with 326 IAC 3 or other methods approved by the commissioner or the U.S. EPA.

Compliance Monitoring Requirements C.8 Compliance Monitoring [326 IAC 2-1.1-11]

Compliance with applicable requirements shall be documented as required by this permit. The Permittee shall be responsible for installing any necessary equipment and initiating any required monitoring related to that equipment. All monitoring and record keeping requirements not already legally required shall be implemented when operation begins.

C.9 Monitoring Methods [326 IAC 3][40 CFR 60][40 CFR 63]

Any monitoring or testing required by Section D of this permit shall be performed according to the provisions of 326 IAC 3, 40 CFR 60, Appendix A, 40 CFR 60, Appendix B, 40 CFR 63, or other approved methods as specified in this permit.

C.10 Compliance Response Plan - Preparation and Implementation

(a) The Permittee is required to prepare a Compliance Response Plan (CRP) for each compliance monitoring condition of this permit. If a Permittee is required to have an Operation, Maintenance and Monitoring (OMM) Plan under 40 CFR 60/63 , such plans shall be deemed to satisfy the requirements for a CRP for those compliance monitoring



conditions. A CRP shall be submitted to IDEM, OAQ upon request. The CRP shall be prepared within ninety (90) days after issuance of this permit by the Permittee, supplemented from time to time by the Permittee, maintained on site, and comprised of:

(1) Reasonable response steps that may be implemented in the event that a

response step is needed pursuant to the requirements of Section D of this permit; and an expected time frame for taking reasonable response steps.

(2) If, at any time, the Permittee takes reasonable response steps that are not set

forth in the Permittee’s current Compliance Response Plan or Operation, Maintenance and Monitoring (OMM) Plan, the Permittee shall amend its Compliance Response Plan or Operation, Maintenance and Monitoring (OMM) Plan to include such response steps taken.

The OMM Plan shall be submitted within the time frames specified by the applicable 40 CFR 60/63 requirement.

(b) For each compliance monitoring condition of this permit, reasonable response steps shall

be taken when indicated by the provisions of that compliance monitoring condition as follows:

(1) Reasonable response steps shall be taken as set forth in the Permittee’s current

Compliance Response Plan or Operation, Maintenance and Monitoring (OMM) Plan; or

(2) If none of the reasonable response steps listed in the Compliance Response Plan

or Operation, Maintenance and Monitoring (OMM) Plan is applicable or responsive to the excursion, the Permittee shall devise and implement additional response steps as expeditiously as practical. Taking such additional response steps shall not be considered a deviation from this permit so long as the Permittee documents such response steps in accordance with this condition.

(3) If the Permittee determines that additional response steps would necessitate that

the emissions unit or control device be shut down, and it will be 10 days or more until the unit or device will be shut down, then the permittee shall promptly notify the IDEM, OAQ of the expected date of the shut down, the status of the applicable compliance monitoring parameter with respect to normal, and the results of the actions taken up to the time of notification.

(4) Failure to take reasonable response steps shall be considered a deviation from

the permit.

(c) The Permittee is not required to take any further response steps for any of the following reasons:

(1) A false reading occurs due to the malfunction of the monitoring equipment and

prompt action was taken to correct the monitoring equipment.

(2) The Permittee has determined that the compliance monitoring parameters established in the permit conditions are technically inappropriate, has previously submitted a request for a minor permit modification to the permit, and such request has not been denied.

(3) An automatic measurement was taken when the process was not operating.



(4) The process has already returned or is returning to operating within “normal” parameters and no response steps are required.

(d) Except as otherwise provided by a rule or provided specifically in Section D, all monitoring

as required in Section D shall be performed when the emission unit is operating, except for time necessary to perform quality assurance and maintenance activities.

Record Keeping and Reporting Requirements C.11 Malfunctions Report [326 IAC 1-6-2]

Pursuant to 326 IAC 1-6-2 (Records; Notice of Malfunction):

(a) A record of all malfunctions, including startups or shutdowns of any facility or emission control equipment, which result in violations of applicable air pollution control regulations or applicable emission limitations shall be kept and retained for a period of three (3) years and shall be made available to the Indiana Department of Environmental Management (IDEM), Office of Air Quality (OAQ) or appointed representative upon request.

(b) When a malfunction of any facility or emission control equipment occurs which lasts more

than one (1) hour, said condition shall be reported to OAQ, using the Malfunction Report Forms (2 pages). Notification shall be made by telephone or facsimile, as soon as practicable, but in no event later than four (4) daytime business hours after the beginning of said occurrence.

(c) Failure to report a malfunction of any emission control equipment shall constitute a

violation of 326 IAC 1-6, and any other applicable rules. Information of the scope and expected duration of the malfunction shall be provided, including the items specified in 326 IAC 1-6-2(a)(1) through (6).

(d) Malfunction is defined as any sudden, unavoidable failure of any air pollution control

equipment, process, or combustion or process equipment to operate in a normal and usual manner. [326 IAC 1-2-39]

C.12 General Record Keeping Requirements [326 IAC 2-6.1-5]

(a) Records of all required monitoring data, reports and support information required by this permit shall be retained for a period of at least five (5) years from the date of monitoring sample, measurement, report, or application. These records shall be physically present or electronically accessible at the source location for a minimum of three (3) years. The records may be stored elsewhere for the remaining two (2) years as long as they are available upon request. If the Commissioner makes a request for records to the Permittee, the Permittee shall furnish the records to the Commissioner within a reasonable time.

(b) Unless otherwise specified in this permit, all record keeping requirements not already

legally required shall be implemented when operation begins. C.13 General Reporting Requirements [326 IAC 2-1.1-11] [326 IAC 2-6.1-2] [IC 13-14-1-13]

(a) Reports required by conditions in Section D of this permit shall be submitted to:

Indiana Department of Environmental Management Compliance Data Section, Office of Air Quality 100 North Senate Avenue MC 61-53 IGCN 1003 Indianapolis, Indiana 46204-2251



(b) Unless otherwise specified in this permit, any notice, report, or other submission required by this permit shall be considered timely if the date postmarked on the envelope or certified mail receipt, or affixed by the shipper on the private shipping receipt, is on or before the date it is due. If the document is submitted by any other means, it shall be considered timely if received by IDEM, OAQ, on or before the date it is due.

(c) Unless otherwise specified in this permit, any reports required in Section D of this permit

shall be submitted within thirty (30) days of the end of the reporting period. The reports do not require the certification by an “authorized individual” as defined by 326 IAC 2-1.1-1(1).

(d) The first report shall cover the period commencing on the date of issuance of this permit

and ending on the last day of the reporting period. Reporting periods are based on calendar years.



SECTION D.1 EMISSIONS UNIT OPERATION CONDITIONS

Facility Description [326 IAC 2-6.1]: (a) One (1) natural gas fired bun oven (identified as Unit A), with a maximum heat input capacity of

4.60 MMBtu per hour and a maximum baking rate of 7,700 pounds of bread per hour, and exhausting at Stack A. This unit was constructed in 1979.

(b) One (1) natural gas fired muffin griddle (identified as Unit B), with a maximum heat input

capacity of 5.96 MMBtu per hour and a maximum baking rate of 2.10 tons of bread per hour, and exhausting at Stack B. This unit was constructed in 1983.


Emission Limitations and Standards [326 IAC 2-6.1-5(1)] D.1.1 Volatile Organic Compounds (VOCs) [326 IAC 2-7]

This source is not subject to the requirements of 326 IAC 2-7 (Part 70 Permit Program) because the potential to emit VOC from the entire source is less than one hundred (100) tons per year. Any change or modification which would increase the potential to emit of VOC equal to or greater than one hundred (100) tons per year must receive prior approval from IDEM, OAQ.

D.1.2 Volatile Organic Compound (VOC) Limitations [326 IAC 8-1-6] The potential to emit VOC from the muffin griddle (identified as Unit B) shall be less than 25.0 tons per twelve (12) consecutive month period with compliance determined at the end of each month.

Compliance with this limit renders the requirements of 326 IAC 8-1-6 (New facilities; General reduction requirements) not applicable.

D.1.3 Particulate [326 IAC 6-3-2]

Pursuant to 326 IAC 6-3-2 (Particulate Emission Limitations for Manufacturing Processes), the particulate emissions from the bun making oven and muffin griddle shall not exceed 10.1 pounds per hour and 5.73 pounds per hour when operating at a process weight rate of 3.85 tons per hour and 1.65 tons per hour, respectively.



E = 4.10 P 0.67 where E = rate of emission in pounds per hour and

P = process weight rate in tons per hour D.1.4 Preventive Maintenance Plan [326 IAC 1-6-3]

A Preventive Maintenance Plan, in accordance with Section C - Preventive Maintenance Plan, of this permit, is required for the bun oven facility.

Compliance Monitoring Requirements [326 IAC 2-5.1-3(e)(2)] [326 IAC 2-6.1-5(a)(2)] D.1.5 VOC Emissions

Compliance with Condition D.1.2 shall be determined within 30 days of the end of each month. For a particular month, this shall be based on the total volatile organic compound emitted for that month added to the previous eleven (11)-month total VOC emitted so as to arrive at VOC



emissions for the most recent twelve (12) consecutive month period. The VOC emissions for a month shall be determined using the following equation:

∑=

=n

1i

iii ton/lbs2000

BEVOC

where:

VOCi = The total VOC emissions per month from the muffin griddle for all bread types; Bi = The amount of bread of type i produced during a given month (tons/month); Ei = The VOC emission factor for type i bread (lb of VOC/ton of baked bread); and n = The total number of bread types produced during a given month.

The VOC emission factor for each type of bread made in the muffin griddle shall be calculated using the following equation:

Ei = 0.40425 + 0.444585 [(Yi x ti) + (S x ts)] where: Ei = The VOC emission factor for type i bread (lb of VOC/ton of baked bread); Yi = The baker’s percent of yeast in sponge; ti = The total time of fermentation in hours; S = The baker's percent yeast added to dough; and ts = The proof time plus the floor time in hours.

D.1.6 Visible Emissions Notations

(a) Visible emission notations of the bun oven stack exhaust shall be performed once per shift during normal daylight operations when exhausting to the atmosphere. A trained employee shall record whether emissions are normal or abnormal.

(b) For processes operated continuously, "normal" means those conditions prevailing, or

expected to prevail, eighty percent (80%) of the time the process is in operation, not counting startup or shut down time.

(c) In the case of batch or discontinuous operations, readings shall be taken during that part

of the operation that would normally be expected to cause the greatest emissions. (d) A trained employee is an employee who has worked at the plant at least one (1) month

and has been trained in the appearance and characteristics of normal visible emissions for that specific process.

(e) The Compliance Response Plan for this unit shall contain troubleshooting contingency

and response steps for when an abnormal emission is observed. Failure to take response steps in accordance with Section C - Compliance Response Plan - Preparation and Implementation shall be considered a violation of this permit.

Record Keeping and Reporting Requirement D.1.7 Record Keeping Requirements

(a) To document compliance with Condition D.1.4, the Permittee shall maintain records of visible emission notations of the bun oven stack exhaust once per shift.

(b) To document compliance with Condition D.1.3, the Permittee shall maintain records of



any additional inspections prescribed by the Preventive Maintenance Plan. (c) To document compliance with Condition D.1.2, the Permittee shall maintain records in

accordance with (1) through (4) below. Records maintained for (1) through (4) shall be taken as stated below and shall be complete and sufficient to establish compliance with the VOC emissions limit established in Condition D.1.2.

(1) The dates of the compliance period:

(2) The amount and type of each bread produced during each month; (3) The VOC emission factor for each type of bread made during each month and

information necessary to calculate the VOC emission factor for each type of bread, including:

(A) The baker’s percent of yeast in sponge;

(B) The total time of fermentation in hours;

(C) The baker's percent yeast added to dough; and

(D) The proof time plus the floor time in hours.

(4) The total weight of VOCs emitted for each month.

(d) All records shall be maintained in accordance with Section C - General Record Keeping

Requirements, of this permit. D.1.8 Reporting Requirements

A quarterly summary of the information to document compliance with Condition D.1.2 shall be submitted to the addresses listed in Section C - General Reporting Requirements, of this permit, using the reporting forms located at the end of this permit, or their equivalent, within thirty (30) days after the end of the quarter being reported.




Facility Description [326 IAC 2-6.1]: (c) Two (2) flour storage silos (identified as Unit C1 and C2), each with a maximum capacity of 60

tons and a maximum throughput rate of 6.25 tons of flour per hour, equipped with a pneumatic conveyance system, using fabric filters as control. These units were constructed in 1979.


Emission Limitations and Standards [326 IAC 2-6.1-5(1)] D.2.1 Particulate [326 IAC 6-3-2]

Pursuant to 326 IAC 6-3-2 (Particulate Emission Limitations for Manufacturing Processes), the particulate emissions from the two (2) flour storage silos shall each not exceed 8.80 pounds per hour when operating at a process weight rate of 3.13 tons per hour.



E = 4.10 P 0.67 where E = rate of emission in pounds per hour and

P = process weight rate in tons per hour Compliance Determination Requirements D.2.2 Particulate Control

In order to comply with Conditions D.2.1, the dry filters used for particulate control shall be in operation and control emissions from the two (2) flour storage silos at all times when the two (2) flour storage silos are in operation.




Facility Description [326 IAC 2-6.1]: (d) One (1) natural gas fired Hurst boiler (identified as Unit D), with a maximum heat input capacity

of 2.60 MMBtu per hour and exhausting at Stack D. This unit was constructed in 1979. (e) One (1) natural gas fired Kewanee boiler (identified as Unit E), with a maximum heat input

capacity of 1.80 MMBtu per hour and exhausting at Stack E. This unit was constructed in 1996.


Emission Limitations and Standards [326 IAC 2-6.1-5(1)] D.3.1 Particulate [326 IAC 6-2-3]

Pursuant to 326 IAC 6-2-3 (e) (Particulate Emission Limitations for Sources of Indirect Heating: emission limitations for facilities specified in 326 IAC 6-2-1 (b)), particulate emissions from all facilities used for indirect heating which were existing and in operation after June 8, 1972, shall in no case exceed 0.6 pounds of particulate matter per million British thermal units heat input. Therefore, the 2.605 MMBtu per hour Hurst boiler shall not exceed 0.6 pounds of particulate matter per MMBtu heat input.

D.3.2 Particulate [326 IAC 6-2-4] Pursuant to 326 IAC 6-2-4 (Particulate emission limitations for sources of indirect heating: emission limitations for facilities specified in 326 IAC 6-2-1 (b)), particulate emissions from the 1.80 MMBtu per boiler, which was constructed after September 12, 1983, shall in no case exceed 0.6 pounds of particulate matter per million British thermal units heat input.




Facility Description [326 IAC 2-6.1]: (f) One (1) 5 KVA emergency generator (identified as Unit G), burning natural gas and exhausting

at Stack G. This unit was constructed in 1983. (The information describing the process contained in this facility description box is descriptive information and does not constitute enforceable conditions.)

Emission Limitations and Standards D.4.1 Limitation on Operating Hours

Operation of one (1) 5 kV emergency generator shall in no case exceed 500 hours of operation per twelve (12) consecutive month period. Any changes to the source that would require operating either emergency generator for more than 500 hours per year must have prior approval from IDEM, OAQ.

Record Keeping and Reporting Requirements [326 IAC 2-5.1-3(e)(2)] [ 326 IAC 2-6.1-5(a)(2)] D.4.2 Record Keeping Requirements

(a) To document compliance with Condition D.4.1, the Permittee shall maintain records of the dates of operation and the number of hours of operation for the generator.

(b) All records shall be maintained in accordance with Section C - General Record Keeping

Requirements, of this permit.




Facility Description [326 IAC 2-6.1]: (g) Six (6) natural gas fired space heaters (identified as F1 through F6), each with a maximum heat

input capacity of 0.10 MMBtu per hour. These units were installed in 1979. (The information describing the process contained in this facility description box is descriptive information and does not constitute enforceable conditions.)

Emission Limitations and Standards

There are no specifically applicable requirements that apply to these emission units.



INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT OFFICE OF AIR QUALITY COMPLIANCE BRANCH

MINOR SOURCE OPERATING PERMIT ANNUAL NOTIFICATION

This form should be used to comply with the notification requirements under 326 IAC 2-6.1-5(a)(5).

Company Name: New Horizons Baking Company Address: 700 W. Water Street City: Fremont, Indiana 46737 Phone #: (260) 495-7055 MSOP #: 151-17821-00060

I hereby certify that New Horizons Baking Company is still in operation.

no longer in operation.

I hereby certify that New Horizons Baking Company is in compliance with the requirements of MSOP 151-17821-00060

not in compliance with the requirements of MSOP 151-17821-00060

Authorized Individual (typed): Title: Signature: Date:

If there are any conditions or requirements for which the source is not in compliance, provide a narrative description of how the source did or will achieve compliance and the date compliance was, or will be achieved.

Noncompliance:



MALFUNCTION REPORT

INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT

OFFICE OF AIR QUALITY FAX NUMBER - 317 233-5967

This form should only be used to report malfunctions applicable to Rule 326 IAC 1-6 and to qualify for the exemption under 326 IAC 1-6-4.

THIS FACILITY MEETS THE APPLICABILITY REQUIREMENTS BECAUSE IT HAS POTENTIAL TO EMIT 25 TONS/YEAR PARTICULATE MATTER ?_____, 25 TONS/YEAR SULFUR DIOXIDE ?_____, 25 TONS/YEAR NITROGEN OXIDES?_____, 25 TONS/YEAR VOC ?_____, 25 TONS/YEAR HYDROGEN SULFIDE ?_____, 25 TONS/YEAR TOTAL REDUCED SULFUR ?_____, 25 TONS/YEAR REDUCED SULFUR COMPOUNDS ?_____, 25 TONS/YEAR FLUORIDES ?_____, 100TONS/YEAR CARBON MONOXIDE ?_____, 10 TONS/YEAR ANY SINGLE HAZARDOUS AIR POLLUTANT ?_____, 25 TONS/YEAR ANY COMBINATION HAZARDOUS AIR POLLUTANT ?_____, 1 TON/YEAR LEAD OR LEAD COMPOUNDS MEASURED AS ELEMENTAL LEAD ?_____, OR IS A SOURCE LISTED UNDER 326 IAC 2-5.1-3(2) ?_____. EMISSIONS FROM MALFUNCTIONING CONTROL EQUIPMENT OR PROCESS EQUIPMENT CAUSED EMISSIONS IN EXCESS OF APPLICABLE LIMITATION ________. THIS MALFUNCTION RESULTED IN A VIOLATION OF: 326 IAC _______ OR, PERMIT CONDITION # _______ AND/OR PERMIT LIMIT OF _______________ THIS INCIDENT MEETS THE DEFINITION OF ‘MALFUNCTION’ AS LISTED ON REVERSE SIDE ? Y N THIS MALFUNCTION IS OR WILL BE LONGER THAN THE ONE (1) HOUR REPORTING REQUIREMENT ? Y N

COMPANY:_________________________________________________________PHONE NO. ( )________________________ LOCATION: (CITY AND COUNTY)______________________________________________________________________________ PERMIT NO. _________________ AFS PLANT ID: _________________ AFS POINT ID: _________________ INSP:___________ CONTROL/PROCESS DEVICE WHICH MALFUNCTIONED AND REASON:________________________________________________________________________________________ DATE/TIME MALFUNCTION STARTED: _____/_____/ 20____ _____________________________________________ AM / PM ESTIMATED HOURS OF OPERATION WITH MALFUNCTION CONDITION:___________________________________________

DATE/TIME CONTROL EQUIPMENT BACK-IN SERVICE______/______/ 20____ _______________ AM/PM

TYPE OF POLLUTANTS EMITTED: TSP, PM-10, SO2, VOC, OTHER:___________________________________________ ESTIMATED AMOUNT OF POLLUTANT EMITTED DURING MALFUNCTION: _________________________________________ MEASURES TAKEN TO MINIMIZE EMISSIONS:_________________________________________________________________ ________________________________________________________________________________________________________ REASONS WHY FACILITY CANNOT BE SHUTDOWN DURING REPAIRS: CONTINUED OPERATION REQUIRED TO PROVIDE ESSENTIAL* SERVICES:_______________________________________ CONTINUED OPERATION NECESSARY TO PREVENT INJURY TO PERSONS:_______________________________________ CONTINUED OPERATION NECESSARY TO PREVENT SEVERE DAMAGE TO EQUIPMENT:____________________________ INTERIM CONTROL MEASURES: (IF APPLICABLE)______________________________________________________________ _________________________________________________________________________________________________________ MALFUNCTION REPORTED BY:___________________________________TITLE:_____________________________

(SIGNATURE IF FAXED) MALFUNCTION RECORDED BY:_______________________DATE:__________________TIME:__________________ *SEE PAGE 2

PAGE 1 OF 2



Please note - This form should only be used to report malfunctions applicable to Rule 326 IAC 1-6 and to qualify for

the exemption under 326 IAC 1-6-4.

326 IAC 1-6-1 Applicability of rule

Sec. 1. This rule applies to the owner or operator of any facility required to obtain a permit under 326 IAC 2-5.1 or 326 IAC 2-6.1. 326 IAC 1-2-39 “Malfunction” definition

Sec. 39. Any sudden, unavoidable failure of any air pollution control equipment, process, or combustion or process equipment to operate in a normal and usual manner. *Essential services are interpreted to mean those operations, such as, the providing of electricity by power plants. Continued operation solely for the economic benefit of the owner or operator shall not be sufficient reason why a facility cannot be shutdown during a control equipment shutdown. If this item is checked on the front, please explain rationale: ________________________________________________________________________ ________________________________________________________________________

PAGE 2 OF 2



INDIANA DEPARTMENT OF ENVIRONMENTAL MANAGEMENT OFFICE OF AIR QUALITY

COMPLIANCE DATA SECTION

MSOP Quarterly Report Source Name: New Horizons Baking Company Source Address: 700 W. Water Street, Fremont, Indiana 46737 Mailing Address: 700 W. Water Street, Fremont, Indiana 46737 MSOP No.: 151-17821-00060 Facility: The muffin griddle (identified as Unit B) Parameter: Volatile Organic Compound (VOC) Emissions Limit: Less than 25.0 tons per twelve (12) consecutive month period, with compliance

determined at the end of each month. The VOC emissions for a month shall be determined using the equations contained in Condition D.1.5

YEAR:_____________________

VOC Emissions (tons) VOC Emissions (tons) VOC Emissions (tons) Month

This Month Previous 11 Months 12 Month Total

No deviation occurred in this quarter. Deviation/s occurred in this quarter.

Deviation has been reported on: ___________________

Submitted by: _____________________________________________________

Title / Position:_____________________________________________________

Signature: ________________________________________________________

Date: ____________________________________________________________

Phone:___________________________________________________________

of 4

Company Name: New Horizons Baking CompanyAddress: 700 W. Water Street, Fremont, Indiana 46737

Minor Permit Revision NO.: 151-26448-00060Reviewer: Timothy R. Pettifor

Date: June 11, 2008

UNCONTROLLED POTENTIAL TO EMIT IN TONS PER YEAREmission Units PM PM10 SO2 NOx VOC CO HAPs


Bun and Muffin Ovens (Combustion) 0.10 0.40 0.03 4.60 0.30 3.90 NegligibleBun Making Ovens (Fermentation) 62.2

Muffin Griddle (Fermentation) 28.6Emergency Generator 3.4E-05 3.4E-05 2.0E-06 2.9E-03 4.0E-04 1.9E-03

Silos 0.96 0.96TOTAL SUM 1.23 1.53 0.04 6.79 91.2 5.74

POTENTIAL TO EMIT AFTER ISSUANCE IN TONS PER YEAREmission Units PM PM10 SO2 NOx VOC CO HAPs


Bun and Muffin Ovens (Combustion) 0.10 0.40 0.03 4.60 0.30 3.90Bun Making Ovens (Fermentation) 62.20

Muffin Griddle (Fermentation) 24.9Emergency Generator 3.4E-05 3.4E-05 2.0E-06 2.9E-03 4.0E-04 1.9E-03

Silos 0.96 0.96TOTAL SUM 1.23 1.53 0.04 6.79 87.5 5.74

Appendix A: Emission CalculationsUpdated 2008 Summary

700 W. Water Street, Fremont, Indiana 46737Minor Permit Revision No.: 151-26448-00060

Reviewer: Timothy R. PettiforDate: June 11, 2008

Unit MMBtu/hrBun Oven 4.60Muffin Griddle 5.96Total 10.56

MMBtu/hr MMCF/yr

10.56 92.5

PM* PM10* SO2 NOx VOC COEmission Factor in lb/MMCF 1.9 7.6 0.6 100.0 5.5 84.0

**see below

0.1 0.4 0.03 4.6 0.3 3.9

Methodology

See page 3 for HAPs emissions calculations.

Emission Factors are from AP 42, Chapter 1.4, Tables 1.4-1, 1.4-2, 1.4-3, SCC #1-02-006-02, 1-01-006-02, 1-03-006-02, and 1-03-006-03(SUPPLEMENT D 3/98)Emission (tons/yr) = Throughput (MMCF/yr) x Emission Factor (lb/MMCF)/2,000 lb/ton

All emission factors are based on normal firing.MMBtu = 1,000,000 BtuMMCF = 1,000,000 Cubic Feet of Gas

Potential Throughput (MMCF) = Heat Input Capacity (MMBtu/hr) x 8,760 hrs/yr x 1 MMCF/1,000 MMBtu

Potential Emission in tons/yr

Pollutant

*PM emission factor is filterable PM only. PM10 emission factor is filterable and condensable PM10 combined.**Emission Factors for NOx: Uncontrolled = 100, Low NOx Burner = 50, Low NOx Burners/Flue gas recirculation = 32

Heat Input Capacity Potential Throughput

New Horizons Baking CompanyCompany Name: Address City IN Zip:

Appendix A: Emissions Calculations Page 2 of 4

Natural Gas Combustion Only MM BTU/HR <100

700 W. Water Street, Fremont, Indiana 46737Minor Permit Revision No.: 151-26448-00060

Reviewer: Timothy R. PettiforDate: April 29, 2008

Benzene Dichlorobenzene Formaldehyde Hexane Toluene2.1E-03 1.2E-03 7.5E-02 1.8E+00 3.4E-03

9.713E-05 5.550E-05 3.469E-03 8.326E-02 1.573E-04

Lead Cadmium Chromium Manganese Nickel5.0E-04 1.1E-03 1.4E-03 3.8E-04 2.1E-03

2.313E-05 5.088E-05 6.475E-05 1.758E-05 9.713E-05

The five highest organic and metal HAPs emission factors are provided above. Additional HAPs emission factors are available in AP-42, Chapter 1.4.

HAPs - Metals

Emission Factor in lb/MMcf


Methodology is the same as page 2.

Address City IN Zip:

HAPs - Organics

Emission Factor in lb/MMcf


MM BTU/HR <100HAPs Emissions

Company Name: New Horizons Baking Company

Page 3 of 4 TSD App AAppendix A: Emissions CalculationsNatural Gas Combustion Only

of 4 TSD App AAppendix A: Emission Calculations

VOC Emissions From One (1) Muffin Griddle

Company Name: New Horizons Baking CompanyAddress: 700 W. Water Street, Fremont, Indiana 46737

Minor Permit Revision No.: 151-26448-00060Reviewer: Timothy R. Pettifor

Date: June 11, 2008

1. VOC Emissions from Bread Baking:

Maximum Baking Rate = 2.10 tons bread per hour

The emission factor for muffin griddle based on the following equation from the American Institue of Bakers - Bakery Oven Ethanol Emissions, Vol IX, Issue 12 (12/87):E.F. (lb VOC/ton of baked bread) = 0.40425 + 0.444585[(Yi x ti) + (S x ts)]

where Baker's percent of yeast in sponge (Yi) = 7.6

Total time of fermentation in hours (ti) = 0.8Baker's percent of yeast added to dough (S) = 0

Proof time + Floor time in hours (ts) = 0

F. (lb VOC/ton) = 0.40425 + 0.444585 [(7.6 x 0.8) + 0] = 3.11

The Potential To Emit of VOC Uncontrolled From Bread Baking =2.10 tons/hour * 3.11 lbs/ton * 8760 hours/year * 1 tons/2000 lbs = 28.6 ton/year

The Emission Factor came from American Institute of Bakers

notice of decision: approval - effective immediatelypermits.air.idem.in.gov/26448f.pdfpursuant to...

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